Sorter supplement control

ABSTRACT

A document reproduction system with processor for making copies, a document handler for feeding documents to be copied to the processor, and a collator to either stack or collate the copies. The collator, which comprises a procession of copy receiving trays, incorporates a copy sensor to prevent reuse of the collator, or at least the portion thereof used previously, until the collator trays are cleared of copies from a previous job. To allow the collator, or the same section thereof to be used regardless, as when it is desired to add copies to a previous job, selectively operable control means are provided to override the aforesaid copy sensor and permit copies in addition to those originally programmed to be placed in the same collator or collator section together with those copies collator previously.

[ Mar. 11, 1975 United States Patent [191 Kukucka SORTER SUPPLEMENT CONTROL Primary Examiner-Even C. Blunk [75] Inventor: William P. Kukucka, Webster, NY. Assistant [hammer-James Miller [73] Xerox Corporation, Stamford,

Conn.

[57] ABSTRACT A document reproduction system with processor for Assignee:

[22] led: 1972 making copies, a document handler for feeding docu- 21 ments to be copied to the processor, and a collator to either stack or collate the copies. The collator, which comprises a procession of copy receiving trays, incorporates a copy sensor to prevent reuse of the collator, or at leastthe portion thereof used previously, until the collator trays are cleared of copies from a previous Appl. No.: 312,167

34 i H1 137 v1 4 6 B/ .l m W8 "5 no ""7 m Wmh c .r "B e "S l C d td UhF 11]] 218 555 [.ll.

271/57 job. To allow the collator, or the same section thereof to be used regardless, as when it is desired to add copies to a previous job, selectively operable control 156] Relerences Cited UNlTED STATES PA'l'EN'l'S means are provided to override the aforesaid copy rr a r w H a own no BIC mm m" .1 D. omo aC s u m w .w mmm F mm m dh .l 8. W .mC a a r '16 4 Whom 9 CO8 .5 t 0 .I. mn C e 0 2 mfi dmm n i b 30 S rru rpm mwmm maOr. SnCp 489 Mmmm l 7 5w7m2 I522 7 27.

Mestre..................

y a H 4366 79 50 OAUQ AJ- s ea 1 //7 //9 H In I SORTER SUPPLEMENT CONTROL This invention relates to a reproduction system, and more particularly, to an improved reproduction system incorporating means to permit copies in addition to the number originally programmed to be integrated into the program.

In reproduction systems incorporating both a high speed processor and collator, the system is normally set by the operator to a predetermined program. The program may result in copies stacked according to pages or according to books, the latter normally being referred to as a collated copy output. The program output, whether stacked or collated, may comprise several copies up to hundreds. To protect against the inadvertent mixing of copies from one program with those of another copy program, as may occur when a second copy program is started before copies of the first program have been cleared from the system collator, protective means are normally provided to prevent reuse of the collator, or at least the collator section last used, until copies from the previous program have been cleared out. While protection of this sort effectively prevents the aforedescribed intermixing of copies of one program with those of another, it also serves to rule out, or at least curtail, the supplementing of a previously run program or job with additional copies unless the collator has been cleared first. It is, however, sometimes advantageous to be able to collate additional copies in with the original program as, for example, where the original document, due to size considerations, cannot be handled normally.

It is a principal object of the present invention to provide a new and improved reproduction system.

It is a further object of the present invention to provide a reproduction system incorporating a control for overriding the job integrity protector of the system to permit additional or supplemental copies to be collated in with those of a previous program.

It is an object of the present invention to provide a control for reproduction systems having a collator designed to permit a copy program or job to be supplemented with additional copies without requiring clearing of the collator first.

It is an object of the present invention to provide an improved collator control to allow the operator to integrate supplemental copies with those of a previous program.

It is-a further object of the present invention to provide a control selectively operable to overrule the collator in use control and permit additional copies to be added to the same collator trays with copies from the previous program.

This invention relates to a reproduction system for producing and collating copies from a set of documents, comprising in combination, a processor; a collator, the collator having at least one copy storage section with trays for receiving copies therein; means for programming the system to provide a preset number of document copies arranged in a predetermined orientation in the collator section; means to prevent other uses of the collator section so long as the program is in process and copies therefrom remain in the trays of the collator section; and means adapted when actuated to override the last mentioned means to permit copies in addition to those programmed to be arranged in the trays of the collator section together with copies previously produced from the program.

These and other objects of the invention will be apparent from the ensuing description and drawings in which:

FIG. 1 is a perspective view of the reproduction system incorporating the improved control of the present invention;

FIG. 2 is a side sectional view showing detail of the processor platen cover and transport;

FIG. 3 is a side sectional view of the reproduction system collator; and

FIG. 4 is a diagram showing schematically the control circuit for the reproduction system of FIG. 1 including the collator control of the present invention.

For a general understanding of reproduction apparatus with which the present invention may be incorporated, reference is made to FIG. 1 wherein various components of a typical electrostatic printer system are illustrated. The printer system is of the xerographic type and is generally designated with the reference numeral 10. As in all xerographic systems, a light image of an original to be reproduced is projected onto the sensitized surface of a xerographic plate to form an electrostatic latent image. Thereafter, the latent image is developed with toner material to form a xerographic powder image corresponding to the latent image on the plate surface. The powder image is then electrostatically transferred to a record material such as a sheet or web of paper or the like to which it may be fused by a fusing device whereby the powder image is caused permanently to adhere to the surface of the record material.

The xerographic processor indicated by the reference numeral 11 is arranged as a selfcontained unit having all of its processing stations located in a unitary enclosure or cabinet. The printer system includes an exposure station at which a light radiation pattern of a document to be reproduced and positioned on a glass platen 12 is projected onto a photoconductive surface in the form of a xerographic belt 13. The document is transported by a recirculating document handler 15 from supply stack 17 on tray 19 to the platen for exposure and then returned to the supply stack on completion of the exposure. This procedure is repeated until the entire stack has been copied at which time'the cycle may be repeated or the documents removed.

As best seen in FIG. 2, document handler 15 includes a belt-type platen transport 14 disposed atop platen 12 for moving documents into and out of copying position on platen 12. Transport 14 is operatively supported on spaced rollers 15, 16, roller 16 being driven by suitable means (not shown) to operate transport 14 forward and backward as required. The entire transport 14 is swingable about the axis of rear drive roller to permit transport 14 to be raised for access to platen l2. Similarly, platen cover 9, which overlays transport 14, is supported for swinging movement about the axis of pin 8 to permit cover 9 to be swung open. This is normally done when it is desired to copy documents manually and to provide service accessibility to the parts.

Suitable illumination means such as flash lamps 18 are provided. The light image is projected by first mirror 20, projection lens 21, and second mirror 23 onto the xerographic belt 13 at the focal plane for the lens 21 at a position indicated by the dotted line 25.

As an interface structure and for unobstructive optical projections, the side of the cabinet is formed with an enlarged rectangular opening to permit the projection of image light rays from the lens 21 to the mirror 23. Similarly, the cabinet forming the document plane is formed with a corresponding rectangular opening that mates with the opening in the printer cabinet when the two cabinets are operatively joined together for copying purposes. Suitable light tight gaskets may be utilized adjacent the exterior of each opening in the cabinets in order to minimize the leakage of unwanted extraneous light.

The xerographic belt 13 is mounted for movement around three parallel arranged rollers 27 suitably mounted in the frame of processor 11. Belt 13 is driven by a suitable motor (not shown) at an appropriate speed. The exposure of-the belt to the light image from the document selectively discharges the photoconductive layer to provide an electrostatic latent image corresponding to the light image projected from the document.

Movement of belt 13 takes the electrostatic latent image past developer apparatus 29 where the electrostatic latent image is developed by a suitable toner in conformance with the charge pattern thereon. After development, the powder image moves to an image transfer station whereat record material, i.e. paper or sheets from either main or auxiliary sheet supply 30, 31, respectively, is brought into image transfer relationship with belt 13 to receive the powder image therefrom. Suitable roll type feeder devices 33 are provided for feeding one sheet at a time from supply stacks 30, 31, the sheet being moved in synchronism with belt 13 during transfer of the developed image and registered with the image on belt 13 by suitable means (not shown).

After transfer, sheets are conveyed to a suitable fuser 34 which fuses or fixes the powder thereon. After fusing, the sheets may be deposited in either copy tray 35 or conveyed to collator 32, a suitable gate (not shown) being provided to selectively route the sheets to either tray 35 or collator 32.

Further details of the processing devices and stations in the printer system may be found in US. Pat. Nos. 3,661,452, issued May 9, 1972, and 3,597,071, issued July 27, 1971, which are commonly assigned with the present invention.

Referring to FIG. 3, collator 32 comprises a base frame 51 which supports upper and lower collator bins 53, 55, respectively. Lower bin 55 includes a unitary framework which defines a series of trays 59 which receive copy sheets in a downward direction. Similarly, upper bin 53 has a unitary framework which defines a series of trays 59 for receiving copy sheets. Trays 59, as well as tray 35 are preferably formed of welded wire or comparable open construction for ease of manufacture. economy, and free passage of air therethrough to minimize air resistance to sheet settlement.

Sheets enter collator 32 through an opening formed in the frame of the lower collating assembly 55. The sheets pass through guides 63 to a pair of pinch rolls 65 and 67 which direct the sheets to either horizontal transport 69 or to vertical transport 129 depending on the position of a deflector 135. Transport 69 is made up of a plurality of horizontal belts 71 driven by motor 153 (FIG. 4). Belts 71 are above the sheet path and free wheeling rollers 73 are positioned below the sheet path. Above rollers 73 are rollers 74 which are positioned within belts 71 and are spring loaded downward to ensure proper traction between the belts and sheets being transported.

Sheets traveling on the horizontal belts 71 are deflected downward into an appropriate tray by fingers or gates 76. Each gate is moved by an individual solenoid 37 in accordance with the solenoid control logic (FIG. 4). As will appear, operation of solenoids 37 is notmally controlled by the passage of a sheet downwardly from horizontal transport 69 into one of the trays 59 which causes the breaking of the light beam established between light source 78 and phototransistor 80. The ensuing signal pulse is relied upon to trigger the next gate solenoid while de-energizing the previous gate solenoid. This results in the gate for the next tray 59 being depressed while the gate to the preceeding tray is raised, suitable spring means (not shown) being pro vided to bias gates 76 in a raised position.

The upper collating bin 53 includes a similar horizontal transport made up of a plurality of horizontal belts 117 driven by a motor 167 which moves above the sheet path and free wheeling rollers 119 positioned below the sheet path. Above rollers 119 are rollers 12] which are positioned within belts 117 to ensure proper traction as in the case ofrollers 74. Gates 123 are provided for each of the trays in upper bin 53, individual solenoids 37 being provided to operate each gate 123 in the same manner as described for gates 76 of lower bin 55. A suitable light and phototransistor combination 125, 127 is provided in bin 53.

As will appear, the system operator may elect to use or not use collator 32 and/or document handler 15. Where collator 32 is not used, copies are stacked in processor tray 35. Where collator 32 is used, the operator may program the system 10 to provide either stacked or collated copy output by actuating the selector S1 or S2, respectively, on control panel 6. Where it is desired to use the document handler 15, either alone or in combination with collator 32, selector S3 or S4 is actuated, selector S3 programming document handler 15 for automatic operation, selector S4 for single document feed. By depressing suitable ones of the switch buttons S5 the number of copies to be made is selected.

Whenever collator selector S1 or $2 is actuated, the sorter logic 301 (FIG. 4) interrogates sensors 303 and 305 to determine whether or not copies, normally from a previous job, are in any of the trays 59 of bins 53, 55. On a signal from either sensor 303 or 305, logic 301 precludes input of copies to the bin 53, 55 affected. This is done by switching deflector to the appropriate position. Should both collator bins 53, 55 have copies therewithin, the joint signals to logic 311 precludes operation of the system 10 until such time as one or both of the bins 53, 55 are cleared.

Sensors 303, 305, which are suitable phototransistors similar to sensors 80 and 127 described earlier, are located in lower and upper collator bins 55 and 53, respectively (FIG. 3). Suitable lamps 306, 307 are provided therefor. Illumination from the lamps 306, 307 will be sensed by sensors 303 and 305 when no sheet material is present in the collator trays. if either or both of the bins are empty, the signal from the collator logic 301 enables operation of processor 11.

Print selector 56 controls start up of the printer system 10. Where either of selectors S3 or S4 is actuated,

document handler 15 will feed the first document from tray 17 to platen 12 of processor 11. With the first document in position, the signal from the document handler logic 313 enables processor 11 to start copying, the resulting copies being deposited in either tray 35 of processor 11 or in collator 32 if one of the collator selectors S1 or S2 has been actuated.

When collator 32 is used, where both bins 53, 55 are empty, deflector 135 is in the position shown in FIG. 3. Copies are therefore routed into lower bin 55 for stacking in trays 59 thereof.

In processor 11, an exposure counter 309 counts flashes of flash lamps 18. It should be understood that the exposure counter could be used with a scan type exposure system as well.

It will be appreciated that phototransistors 80, 127 count the copies entering the trays, the signals from one of phototransistors 80, 127 being fed via OR circuit 302 to copy counter 415 which may comprise any suitable counting device and which in cooperation with logic 301 controls the position of tray deflectors 72, 123 as will appear. In addition, logic 301 controls starting and stopping of the individual collator bin motors 153, 167, as well as the position of bin deflector 135.

The signal output of copy counter 415 controls selectively through collator logic 301 the appropriate solenoid matrix circuits 427, 429 for collator bins 53, 55. Matrix circuits 427, 429 control operation of the bin deflector solenoids 37 to raise and lower the individual fingers 76, 123, respectively. Collator logic 301 includes a suitable comparison circuit (not shown) which serves to compare the number of copies programmed with the number of copies delivered as recorded by copy counter 415.

Printer system may be programmed for a collated copy output with multiple document feed by actuating selectors S2 and S3. During system operation in this mode, collator logic 301 stops the solenoid matrix circuit 427 or 429 for the collator section 53 or 55 then in use from a starting position wherein the first copy produced is routed into the first collator tray through a series of steps equal to the number of copies programmed or the total tray capacity of the collator bin, whichever is less, in accordance with the copy program. Whenever the total number of copies programmed or the collator tray capacity is reached by processor 11, the signal from counter 309 to processor logic 311 stops the processor 11 while actuating document handler 15 to remove the document on platen 12 and bring up the next succeeding document. Following this, operation of processor 11 resumes.

In the meantime, as the last copy of the document previously on platen 12 is deposited in the appropriate collator tray, the signal from copy counter 415 causes collator logic 301 to reset the deflector control matrix 427 or 429 for the collator section then in use so that the first copy of the new document is directed into the first tray of the collator bin.

The above process continues until the number of copies programmed is reached or until the last document in the document handler tray 17 is processed. Where the copy cycle is completed, a signal from counters 309, 415 cycles out the reproduction system 10. However, where the last document is copied but the program is not finished, the copy cycle is automatically repeated. In this circumstance document handler functions to refeed the first document from document tray 17 to platen 12 of processor 11 in preparation for resumption of the copying process.

However, before processor 11 can commence operation, the signal input from the appropriate detector 303 or 305 to collator logic 301 reflecting the presence of copies in the collator bin just used, is responded to by collator logic 301 which actuates deflector to route the next batch of copies into the other empty collator bin. The copy cycle then continues, the copies generated by processor 11 being deposited in the trays of the other collator bin until either the program is completed, at which point the system cycles out, or the copy capacity of the bin then in use is reached. ln this latter case, following copying of the last document, the document handler 15 again recycles the documents to bring the first document into position on platen 12. At this point, the signal input from the detector 303 or 305 of the collator section last used will be responded to by the collator logic 301 which will switch deflector gate 135 so as to route the next batch of copies into the other collator section if that collator section is empty. If the other collator section has not been cleared of copies, and no other empty collator section is available, the signals from both detectors 303, 305 to collator logic 301 inhibits further operation of the printer system 10 until such timeas at least one of the collator bins is empty.

It is understoodthat the reproduction system 10 may be operated in a stack mode wherein the copies of each document produced by processor 11 are stacked together in the various trays of collator 32 starting with the first tray of whichever bin 53 or 55 is in use. ln this mode of operation one document at a time is positioned on platen 12, either automatically by document handler 15 or manually by the operator, the latter through the expediency of raising to document transport assembly 14 and cover 9 to expose platen 12, placing the document thereon, and then reclosing the transport and cover. It is understood that processor logic control 311 is programmed for the number of copies to be made by actuating appropriate ones of the switches S5. At the same time, selector S1 is actuates to set the collator logic 301 to stack mode and selector S4 is actuated to set document handler logic 313 to single feed mode if document handler 15 is to be used.

In this mode of operation, when the total number of copies programmed for the document being copied is reached, as indicated by counter 309, process 11 cycles out and the document on platen 12 is removed by document handler 15. When the last copy thereof enters the first tray of the collator bin 53 or 55 in use, the signal from copy counter 415 to collator logic 301 actuates the appropriate matirx circuit 427, 429 to raise thedeflector finger of the first tray while depressing the finger for the next succeeding collator tray. The system is accordingly ready to process the next document in tray 17. Processor 11 may then be restarted to copy the second document in accordance with the previously established program.

The aforedescribedprocess continues until all the original documents have been copied, the copies of each document being stacked in successive ones of the collator trays. If, during the program, copies are stacked in the last tray of the bin being used, the signal from the appropriate bin detector 303, 305 to logic 301 switches bin deflector 135 to thereafter direct copies into the other empty bin.

As will be understood, the collator trays of collator 32 have a limited sheet storage capacity. To protect against overfilling of an individual collator tray, a suitable counter circuit 500 is provided, circuit 500 serving to identify the copy storage capacity of the individual collator trays 59.

The output of circuit 500 is fed to a suitable comparator circuit 501 having a second input from copy counter 415. The output of comparator circuit 501 is fed to collator logic 301 controlling bin matrixes 427, 429.

Enabling of circuit 500 may be controlled by collator logic 301 in response to actuation of collator stack selector S1. Circuit 500 is not normally required when collator collating selector S2 is actuated where the capacity of document handler 15 does not exceed the copy capacity of the individual collator trays 59. In this circumstance, as will be understood, the number of copies made when collating cannot exceed the copy capacity of the individual collator trays. Where, however, the document handler 15 can handle a number of documents in excess of the capacity of the individual collator trays, counter circuit 500 may be arranged to be enabled whenever collator 32 is used.

During operation of reproduction system 10 in the stacking mode, effected by actuating selector S1, with or without actuation of selector S4 depending on whether or not it is desired to feed the documents automatically by document handler or manually through the expediency of raising platen cover 19 and transport 14, when the number of copies fed to the tray in use equals the predeterminated tray capacity as determined by circuit 500, comparison circuit 501 is triggered. The other signal from circuit 501 to logic circuit 301 actuates the matrix circuit 427, 429 for the collator bin 53 or 55 in use to release the finger 76, 123 for the tray then in use and depress the finger for the next collator tray. Succeeding copies of the program are therefore routed into the next collator tray. If the capacity of the next tray is insufficient, circuit 500 will respond again when the capacity of the tray is reached to cause logic 301 to step to the next collator tray, and so forth and so on until the program is completed.

On completion of the copy program for the document then on platen 12, the signal from copy counter 415 to collator logic 301 switches to the next succeeding empty collator tray or bin as the case may be and copies of the next document enter the next succeeding tray or bin.

It will be understood the counter circuit 500 and comparison circuit 501 may be replaced by individual sheet detectors in each of the collator trays adapted to generate a signal whenever the number of sheets in the tray reach a predetermined number. In this circumstance the signal would be fed directly to sorter logic 301.

To enable the operator to supplement or add copies to a previously run program, a job supplement control S7 is provided on control panel 6. A suitable override circuit 511 selectively transmits signals from bin detectors 303, 305 to sorter logic 301, circuit 511 being adapted when actuated to negate the signal input from the bin detector 303 or 305 of the bin last used to collator logic 301. it is understood that signals from processor logic 311 serve to identify the proper collator bin 53 or 55.

In use, when the operator desires to add copies to the collator bin 53 or 55 last used before clearing the bin of copies, job supplement control S7 is activated to trigger circuit 511 and block the bin use signal from the appropriate detector 303, 305. Thus, an actuation of print control S6, the interrogation by logic 301 of sensors 303, 305 does not produce a response for the sensor affected and restart of the reproduction system 10 is enabled without switching to the next empty bin. This results in additional copies being disposed in the trays of the previously used collator bin atop the copies from the previous program or job.

As described earlier, processor 11 includes both main and auxiliary paper supply trays 30, 31, respectively. To facilitate the aforedescribed job supplement, arrangements may be made to draw paper from the auxiliary tray 31 whenever control S7 is actuated. This gives the operator the option of using different type paper, i.e., different colored paper, or different size paper, or preprinted paper, etc. when doing a job supplement. Inthis circumstance triggering of circuit 511 inputs a signal to processor logic 311 which enables auxiliary paper tray 31 while disabling the main paper tray While the invention has been described with reference to the structure disclosed, it is not confined to the details set forth, but is intended to cover such modifications or changes as may come within the scope of the following claims.

What is claimed is:

1. In a reproduction system for producing and col lecting copies from a set of documents, the system in cluding a processor and a collator, said collator having at least one copy storage section with trays for receiving copies therein, the improvement comprising:

means for programming said system to provide a preset number of document copies arranged in collated order in said collator section,

copy sensing means including a light source and light responsive means in alignment with said light source in said collator, presence of a copy in said collator trays blocking passage of light from said light source to said sensing means,

control means to prevent start-up of said system unless said sensing means senses the light from said light means, and

means adapted when actuated to override said control means to permit copies in addition to said preset number of document copies to be arranged in the trays of said collator section together with said preset number of document copies produced from said program.

2. The reproduction system according to claim 1 in which said system includes main and auxiliary trays for supplying copy material to said processor;

said override means being adapted when actuated to switch said processor from said main tray to said auxiliary tray. 

1. In a reproduction system for producing and collecting copies from a set of documents, the system including a processor and a collator, said collator having at least one copy storage section with trays for receiving copies therein, the improvement comprising: means for programming said system to provide a preset number of document copies arranged in collated order in said collator section, copy sensing means including a light source and light responsive means in alignment with said light source in said collator, presence of a copy in said collator trays blocking passage of light from said light source to said sensing means, control means to prevent start-up of said system unless said sensing means senses the light from said light means, and means adapted when actuated to override said control means to permit copies in addition to said preset number of document copies to be arranged in the trays of said collator section together with said preset number of document copies produced from said program.
 1. In a reproduction system for producing and collecting copies from a set of documents, the system including a processor and a collator, said collator having at least one copy storage section with trays for receiving copies therein, the improvement comprising: means for programming said system to provide a preset number of document copies arranged in collated order in said collator section, copy sensing means including a light source and light responsive means in alignment with said light source in said collator, presence of a copy in said collator trays blocking passage of light from said light source to said sensing means, control means to prevent start-up of said system unless said sensing means senses the light from said light means, and means adapted when actuated to override said control means to permit copies in addition to said preset number of document copies to be arranged in the trays of said collator section together with said preset number of document copies produced from said program. 